Optimized nuclear fuel core design for a small modular reactor

ABSTRACT

A fuel core for a nuclear reactor in one embodiment includes an upper internals unit and a lower internals unit comprising nuclear fuel assemblies. The assembled fuel core includes an upper core plate, a lower core plate, and a plurality of channel boxes extending therebetween. Each channel box comprises a plurality of outer walls and inner walls collectively defining a longitudinally-extending interior channels or cells having a transverse cross sectional area configured for holding no more than a single nuclear fuel assembly in some embodiments. A cylindrical reflector circumferentially surrounds channel boxes and is engaged at opposing ends by the upper and lower core plates. Adjacent cells within each channel box are formed on opposite sides of inner walls such that the cells are separated from each other by the inner walls alone without any water gaps therebetween which benefits neutronics for some small modular reactor designs.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

The present application is a divisional of U.S. patent application Ser.No. 15/927,284 filed Mar. 21, 2018, which claims the benefit of U.S.Provisional Patent Application Ser. No. 62/474,396 filed Mar. 21, 2017;the entireties of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present application generally relates to nuclear reactors suitablefor power generation facilities, and more particularly to a nuclear fuelcore for such reactors.

A majority of nuclear reactors operating in the world today use light orordinary water to remove heat from the fuel. Generally speaking, thesewater-cooled reactors use heat generated by a nuclear chain reaction toheat or boil water, combined with a Rankine steam cycle, to produceelectricity. There are two general types of Light Water Reactors(LWRs)—Boiling Water Reactors (BWRs) and Pressurized Water Reactors(PWRs). BWRs operate at a pressure near 1000 psi and use nuclear heat toboil water directly in the reactor vessel, whereas PWRs operate at amuch higher pressure of about 2250 psi, to prevent boiling in thereactor vessel. In PWRs, reactor water heat is transferred to asecondary steam generator circuit, where steam produced from boiling issubsequently used to produce electricity. Accordingly, the reactor coresof currently operating PWRs differ significantly from the reactor coresof BWRs in design and operating conditions.

PWR reactors cores are generally housed within a pressure vessel knownas a reactor pressure vessel or simply reactor vessel which circulatesprimary coolant water through the core. A typical nuclear reactor corein a light water reactor comprises a multiplicity of tightly packed“nuclear fuel assemblies” (also referred to as nuclear fuel bundles)which generally may be of square cross section in the U.S. Each nuclearfuel assembly is generally an assemblage of multiple “nuclear fuel rods”which are sealed hollow cylindrical metal tubes (e.g. stainless steel orzirconium alloy) packed with enriched uranium fuel pellets and integralburnable poisons arranged in an engineered pattern to facilitate asuniform a “burning” profile of the nuclear fuel assembly (in both theaxial and cross sectional/transverse directions) as possible. Controlrod assemblies in a PWR are generally removably inserted directly intothe fuel assemblies from above between the fuel rods and used toregulate the nuclear fission reaction. In a BWR, the control assembliesare generally inserted between fuel assemblies from the bottom.

The spacing and arrangement of nuclear fuel assemblies in the reactorcore may significantly affect the neutronics. Neutronics relates to thephysics of neutrons and their travel through materials in the core andthe resulting fission reactions. Neutronics therefore affects theperformance and power level of the reactor. In conventional PWRreactors, the fuel assemblies are arranged in an open lattice withoutany physical barriers between them. This creates homogeneous thermalhydraulic conditions since there is no hydraulic isolation of each fuelassembly from adjacent assemblies. For some PWR reactor core designssuch as the current small modular reactor (SMR) design platform, thisconventional arrangement may detrimentally affect the desiredneutronics.

Improvements are desirable in PWR cores especially for SMRs.

SUMMARY OF THE INVENTION

A nuclear reactor fuel core suitable for a small modular reactor (SMR)is provided which is configured and constructed to improve theneutronics of the reactor. In one embodiment, the reactor fuel core maycomprise a fuel assembly support system including plurality ofvertically-extending channel boxes each configured to hold a pluralityof fuel assemblies therein. The channel boxes provide channeled flow ofprimary coolant in the reactor vessel through the fuel assembly. Thechannel boxes may have a rectangular prismatic or cuboid configurationin some embodiments. Each channel box may comprise perpendicularlyoriented external or outer walls and internal or inner walls whichintersect the outer walls perpendicularly in one embodiment. The innerwalls divide the space within each channel box into a plurality ofinterior channels or cells each having a transverse cross sectionconfigured for holding no more than a single nuclear fuel assembly.Adjacent cells within each channel box formed on opposite sides of theinner walls are separated from each other by the single thickness innerwalls alone with no open water gaps formed therebetween which therebybenefits the neutronics of the core. Advantageously, the inner wallstructure of the channel boxes further serve to structurally reinforcethe channel box to eliminate or minimize neutron induced permanentbowing or deformation over time which adversely affects full and properinsertion of reaction control rods.

The present channel boxes function to thermally and hydraulicallyisolate the fuel assemblies from each other. The channel boxes serve assemi-permanent metallic boxes, which remain within the fuel core whenthe nuclear fuel assemblies are replaced for refueling the reactor.Combination of the channel boxes and cruciform control rod blades in oneembodiment facilitates a significant reduction in the number and cost ofcontrol elements required (as compared with PWR-conventional rod controlclusters assemblies and un-channeled cores), and operational safety viasubstantial core shutdown margin and reactivity control of the reactor.

The small modular reactor disclosed herein may be a natural circulationPWR. The lack of primary coolant circuit cooling pumps dictates that SMRcore design/geometry differ from traditional pumped-flow PWRs to aidsuch natural circulation which relies on temperature differentials asthe means to induce and create flow of primary coolant through thereactor vessel and accompany steam generator. In some embodiments, thepresent SMR may operate at a design temperature of about 610 degrees F.and a pressure of 2500 psia (2250 psia nominal) to induce gravity flowcirculation of primary coolant. The nuclear and thermal hydraulicperformance (for optimized core performance and flow stability) requiresthe design to be able to control the flow distribution radially. Thepresent SMR design advantageously adapts critical geometry aspects foundin both BWRs and PWRs and modifies them to enhance the nuclear andthermal performance of the core, and neutronics.

In one aspect, a nuclear fuel core for supporting nuclear fuelassemblies includes: a longitudinal axis; an upper core plate; a lowercore plate; a plurality of vertically elongated channel boxes extendingbetween the upper and lower core plates, each channel box comprisingouter walls and inner walls collectively defining a plurality oflongitudinally-extending interior cells each having a transverse crosssectional area configured for holding no more than a single nuclear fuelassembly; and a cylindrical reflector circumferentially surrounding thechannel boxes, the upper and lower core plates coupled to opposing endsof the reflector; wherein adjacent cells within each channel box areseparated from each other by the inner walls.

In another aspect, a nuclear fuel core for a nuclear reactor includes: alongitudinal axis; an upper core plate; a lower core plate; a pluralityof vertically elongated prismatic channel boxes extending between theupper and lower core plates, each channel box comprising a plurality ofouter walls and inner walls collectively defining a plurality oflongitudinally-extending interior cells each containing a single nuclearfuel assembly, each channel box separated from adjacent channel boxes byperipheral water gaps formed between the outer walls of the channelboxes; a plurality of cruciform control rods slideably inserted throughthe peripheral water gaps from above the upper core plate for verticalmovement between the channel boxes; and a cylindrical reflectorcircumferentially surrounding the channel boxes, the upper and lowercore plates engaging opposing ends of the reflector; wherein the fuelassemblies within each channel box are separated from each other by theinner walls.

In another aspect, a nuclear fuel core for a nuclear reactor includes: avertically elongated reactor vessel defining an internal cavity and alongitudinal axis; an upper internals unit disposed in the internalcavity, the upper internals unit comprising: a top support plate, anupper core plate spaced vertically apart from the top support plate, andan intermediate support plate spaced therebetween; a plurality of flowtubes extending between the intermediate support plate and upper coreplate; and a plurality of tie rods coupling the top support plate to theupper core plate through the intermediate support plate to form aself-supporting assemblage removably insertable in the reactor vessel asa single unit; a lower internals unit disposed in the internal cavitycomprising a plurality of fuel assemblies defining a fuel core, thelower internals unit further comprising: a plurality of verticallyelongated channel boxes extending between the upper core plate of theupper internals unit and a lower core plate, each channel box comprisinga plurality of outer walls and a plurality of inner walls collectivelydefining a plurality of longitudinally-extending interior cells eachcontaining a single nuclear fuel assembly; and a cylindrical reflectorcircumferentially surrounding the channel boxes, the upper and lowercore plates disposed on opposing ends of the reflector; wherein eachchannel box is vertically aligned with a respective flow tube in theupper internals unit to form a flow path therebetween. In variousembodiments, the fuel assemblies within each channel box are separatedfrom each other by the inner walls, each channel box is separated fromadjacent channel boxes by peripheral water gaps formed between the outerwalls of the channel boxes, and a plurality of cruciform control rodsare slideably inserted in the peripheral water gaps for verticalmovement therein to control reactivity in the reactor.

It is to be understood that the various aspects and features of theinvention described herein can be combined in many various ways andcombinations. Moreover, further areas of applicability of the presentinvention will become apparent from the detailed description providedhereinafter. It should be understood that the detailed description andspecific examples, while indicating the preferred embodiment of theinvention, are intended for purposes of illustration only and are notintended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the exemplary embodiments will be described withreference to the following drawings in which like elements are labeledsimilarly, and in which:

FIG. 1 is a perspective view of a nuclear reactor pressure vesselincluding a fuel core according to an embodiment of the presentdisclosure;

FIG. 2 is a side view thereof;

FIG. 3 is a longitudinal cross-sectional view thereof showing an upperinternals unit and a lower internals unit (fuel core) of the reactor inthe reactor vessel;

FIG. 4 is top perspective view of the reflector assembly of the fuelcore with fuel assemblies and other internals removed for clarity;

FIG. 5 is bottom perspective view thereof;

FIG. 6 is close-up view taken from FIG. 5;

FIG. 7 is a side view of the reflector assembly of FIG. 4;

FIG. 8 is cross-sectional view thereof;

FIG. 9 is a top plan view thereof;

FIG. 10 is a bottom plan view thereof;

FIG. 11 is top perspective view of the fuel core similar to FIG. 4 butshowing the fuel assembly, channel boxes, control rods, and otherappurtenances in place;

FIG. 12 is a close-up view taken from FIG. 11;

FIG. 13 is a side cross-sectional view of the fuel core of FIG. 11;

FIG. 14 is a close-up view taken from FIG. 13;

FIG. 15 is a transverse cross-sectional view taken from FIG. 7;

FIG. 16 is a top plan view of the lower core plate of the fuel core;

FIG. 17 is a cross-sectional view thereof taken from FIG. 16;

FIG. 18 is a top perspective view thereof;

FIG. 19 is a bottom perspective view;

FIG. 20 is a top perspective view of the upper internals unit of thereactor vessel;

FIG. 21 is a bottom perspective view thereof;

FIG. 22 is a top perspective view thereof with the intermediate supportplate removed to reveal the open tops of the flow tubes of the upperinternals unit;

FIG. 23 is top plan view of the upper core plate of the upper internalsunit which is disposed at the bottom of the flow tubes;

FIG. 24 is a side cross-sectional view thereof;

FIG. 25 is partial cross-sectional perspective view showing theassembled upper and lower internals unit (fuel core) and internalcomponents of each;

FIG. 26 is perspective view of a channel box of the lower internals unit(fuel core) with a fuel assembly partially inserted in one of the cellsof the box;

FIG. 27 is a close-up view taken from FIG. 26;

FIG. 28 is a perspective view of a cluster of three channel boxesshowing a cruciform control rod partially inserted between the boxes ina water gap;

FIG. 29 is a close-up taken from FIG. 28 showing details of the controlrod construction;

FIG. 30 is a top perspective view of a cluster of four channel boxesshowing the control rod partially inserted between corner regions of theboxes in the water gap;

FIG. 31 is a top plan view thereof;

FIG. 32 is top perspective view of one embodiment of a single channelbox of square cross-sectional shape configured for holding multiple fuelassemblies (four in this example);

FIG. 33 is a bottom perspective view thereof;

FIG. 34 is a side view thereof;

FIG. 35 is a top close-up view taken from FIG. 32;

FIG. 36 is an exploded view of the channel box showing an exemplaryembodiment of one construction of the box;

FIG. 37 is a bottom close-up view taken from FIG. 33;

FIG. 38 is top plan view of the channel box;

FIG. 39 is a bottom plan view thereof;

FIG. 40 is a transverse cross-sectional of the channel box taken fromFIG. 34;

FIG. 41 is a longitudinal cross-sectional view of the channel box takenfrom FIG. 38;

FIG. 42 is a perspective view of a second channel box of rectangularcross-sectional shape usable in the fuel core;

FIG. 43 is a top plan view of the fuel core showing a combination offuel assemblies and neutron reflection inserts variously installed inselect cells of the channel boxes; and

FIG. 44 is a perspective view of an intermediate support plate of theupper internals unit.

All drawings are schematic and not necessarily to scale. Parts given areference numerical designation in one figure may be considered to bethe same parts where they appear in other figures without a numericaldesignation for brevity unless specifically labeled with a differentpart number and described herein

DETAILED DESCRIPTION

The features and benefits of the present disclosure are illustrated anddescribed herein by reference to exemplary (“example”) embodiments. Thisdescription of exemplary embodiments is intended to be read inconnection with the accompanying drawings, which are to be consideredpart of the entire written description. Accordingly, the presentdisclosure expressly should not be limited to such embodimentsillustrating some possible non-limiting combination of features that mayexist alone or in other combinations of features; the scope of theclaimed invention being defined by the claims appended hereto.

In the description of embodiments disclosed herein, any reference todirection or orientation is merely intended for convenience ofdescription and is not intended in any way to limit the scope of thepresent invention. Relative terms such as “lower,” “upper,”“horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and“bottom” as well as derivative thereof (e.g., “horizontally,”“downwardly,” “upwardly,” etc.) should be construed to refer to theorientation as then described or as shown in the drawing underdiscussion. These relative terms are for convenience of description onlyand do not require that the apparatus be constructed or operated in aparticular orientation. Terms such as “attached,” “coupled,” “affixed,”“connected,” “interconnected,” and the like refer to a relationshipwherein structures are secured or attached to one another eitherdirectly or indirectly through intervening structures, as well as bothmovable or rigid attachments or relationships, unless expresslydescribed otherwise.

FIGS. 1-25 depict a non-limiting embodiment of a nuclear pressurizedwater reactor (PWR) in the form of a small modular reactor (SMR)including a reactor pressure vessel 100 (“reactor vessel” for brevityhereafter) comprising a fuel core with a fuel assembly support systemaccording to the present invention which exhibits improved neutronics.

Reactor vessel 100 comprises a longitudinal axis LA, top head 101,bottom head 102, and a cylindrical shell 103 extending between theheads. Top head 101 may be bolted to the shell 103 in one embodiment toaccess the core, or welded in other embodiments. Reactor vessel 100defines a longitudinally extending internal cavity 104 configured forholding the reactor internals. The reactor internals include an upperinternals unit 110 and lower internals unit 112 (see, e.g. FIGS. 3 and25). The lower internals unit 112 contains the fuel assemblies 124 anddefines the nuclear fuel core 120. The upper internals unit 110 providesa structure for movably supporting and guiding the control rods 150inserted in the fuel core to control the reaction and power output. Thelower internals unit 112/fuel core 120 (shown schematically in FIG. 3)is disposed within cavity 104 in a lower portion of the reactor vessel.The upper portion of the cavity 104 of the reactor vessel 100 containsthe upper internals unit 110 which is vertically stacked on top of thelower internals unit 112 which the reactor is fully assembled.

Referring particularly to FIGS. 20-25, the upper internals unit 110comprises a metallic tubular shell or shroud 107 of cylindrical shapewhich is removably inserted within the reactor vessel cavity 104 on topof the fuel core 120 (lower internals unit 112). Shroud 107 is in fluidcommunication with reactor core 120, and closely coupled thereto forupflow of primary coolant from through the core directly into the shroudwhich forms a riser. Shroud 107 is spaced inwardly from the interiorsurface of shell 103 and concentrically aligned thereto. This defines anannular downcomer region 108 between the shell and shroud. Shroud 107may be formed of a corrosion resistant metal, such as for examplestainless steel or other materials.

The upper internals unit 110 further includes (from top to bottom) a topsupport plate 135, intermediate support plate 139, and an upper coreplate 125 arranged in vertically spaced relationship. The foregoingplates may be formed of a suitable metal such as steel or other. Thespace between the top and intermediate support plates 135, 139 withinshroud 107 defines an upper flow plenum 165. A plurality of rectangularprismatic shaped metallic flow tubes 166 extend vertically between theintermediate support plate 139 and upper core plate 125. The flow tubesmay have a rectilinear transverse cross-sectional shape and can includea combination square tubes 166 a and rectangular tubes 166 b in crosssection which become axially aligned with complementary configuredchannel boxes 130 when installed in the reactor vessel 100, as furtherdescribed herein. The flow tubes 166 have open tops and bottoms and arein fluid communication with each fuel assembly 124 disposed in the fuelcore 120 below for receiving circulating primary coolant from thechannel boxes.

Referring particularly to FIGS. 15-19, the upper core plate 125comprises an open metal lattice or grid structure defining a pluralityof rectilinear cells or flow openings 127 each configured to fluidlycommunication with a single channel box 130 disposed in the fuel core120, as further described herein. When inserted into the reactor vessel100, the upper core plate 125 may abuttingly engage the tops of theplurality of channel boxes 130 to form a relatively tight fluidconnection. In one embodiment, as shown, the flow openings 127 mayinclude a combination of square openings 127 a for mating with channelboxes 130 having a square transverse cross section and rectangularopenings 127 b for mating with channel boxes having a rectangulartransverse cross section. The flow openings 127 are arranged in spacedapart linear horizontal rows (as shown) separated transversely extendingportions of the grid body structure. The upper core plate 125 mayinclude a polygonal-shaped perimeter portion with a multiple steppedconfiguration arranged to engage the complementary configured multiplestepped interior surface 200 of the cylindrical reflector 121 (see, e.g.FIG. 4) to operably key and lock the upper core plate in rotationalposition relative to the cylindrical reflector. The upper core plate 125further includes tie rod openings 142 for inserting tie rods 134therethrough which hold the upper internals unit 110 together, asfurther described herein.

A plurality of cruciform shaped control rod openings 171 formed in theupper core plate 125 slideably receive a complementary configuredcruciform shaped bladed portion of a control rod 150 therein (see, e.g.FIG. 30). The control rod openings 171 are arranged in a wide arraycovering the full extent of the upper core plate 125. Each control rodopening 171 may be disposed proximate to adjacent corner regions formedbetween the square and/or rectangular cells 127, as shown. This allowsthe control rods to be inserted between channel boxes 130 in the fuelcore 120 in peripheral water gaps 157 formed between adjacent channelboxes, and not inside the fuel assemblies. Unlike a PWR core comprisedof large (e.g., 8″×8″) conventional PWR fuel assemblies that uses rodcluster control assemblies (RCCAs) inserted into guide tubes within thefuel assemblies, reactivity in the present SMR fuel core 120 isregulated by control blades that are cruciform in shape, located outsideof the fuel assemblies, and which are inserted from the top of the core.This advantageously allows for a substantial reduction of the number ofcontrol rod drive mechanisms (CRDMs) required to achieve sufficientreactivity control and shutdown margin. In addition, inserting controlblades outside of the channel box 130 assemblies allows for unobstructedpaths from the top of the reactor pressure vessel for insertion ofin-core instruments within fuel assemblies 124 (e.g., inside of thechannel boxes) needed to monitor core power distributions. Possibleinterference from neighboring components in the core is thus avoidedwhich might snag and impede full insertion of the control rods 150. Thisfurther advantageously eliminates the need for penetrations at thebottom of the reactor pressure vessel for both control rod drives andin-core instruments for example.

The intermediate support plate 139 (best shown in FIG. 44) is similarlya metal lattice or grid structure which includes a plurality ofrectilinear shaped flow openings 167 which place the flow tubes 166 influid communication with upper flow plenum 165. Flow tubes 166 aretherefore each axially aligned with a respective flow opening in theintermediate support plate 139 and a respective flow opening 127 in theupper core plate 125 (see, e.g. FIGS. 23-24) which also places each flowtube in fluid communication with the fuel core 120, as further describedherein. Interspersed between flow openings 166 are a plurality ofcruciform shaped openings 170 of similar configuration to and for thesame purpose as cruciform shaped openings 171 in the upper core plate125.

A plurality of metal control rod guide tubes 172 extend between the topand intermediate support plates 135, 139. Each tube 172 is coaxiallyaligned with one of a plurality of circular holes 173 formed through thetop support plate 135 and one of the cruciform control rod openings 170in the intermediate support plate 139. It bears noting that the controlrod guide tubes 172 may have diameters larger than holes 173 in the topsupport plate 135 to define spacers which hold the top support plate 135in spaced relation to the intermediate support plate 139 when the upperinternals assembly is compressed by the tie rods 134.

The upper internals unit 110 of the reactor may therefore be heldtogether by a plurality of vertically-extending tie rods 134 in oneembodiment which are fastened to each of the top support plate 135 andupper core plate 125 by fasteners such as threaded nuts 174. Tie rodholes 175 in the intermediate support plate 139 allow the tie rods 134to pass completely through this plate without engagement. When the upperinternals unit 110 is assembled, the tie rods 134 are tightened whichcompresses the control rod guide tubes 172, intermediate support plate139, and flow tubes 166 between the top support plate 135 and upper coreplate 125 forming a self-supporting assemblage or structure which can betransported and inserted into or removed from the cavity 104 of thereactor vessel 100 as single unit. It bears noting that the space formedbetween the intermediate support plate 139 and upper core plate 125within shroud 107 provides a compartment or area in the upper internalsunit 110 for selectively withdrawing the cruciform shaped control rods150 to control the nuclear reaction and power production. The controlrods 150 are vertically movable up and down in this compartment betweenthe flow tubes 166.

In operation, core cooling water referred to as “primary coolant” in theart circulates through the reactor vessel 100, upper internals unit 110,and fuel core 120 (lower internals unit 112) between a primary coolantinlet nozzle 105 and a primary coolant outlet nozzle 106. In oneembodiment, the inlet and outlet nozzles 105, 106 may be combined in asingle common primary coolant fluid coupling 109 connected directly tothe shell 103 of reactor vessel 100 as shown. In one construction, thecombined inlet-outlet flow nozzles 105/106 may be formed by twoconcentric hollow forgings which define the outer inlet nozzle 105 andthe inner outlet nozzle 106. Inlet nozzle 105 is therefore nested insideoutlet nozzle 106 in this arrangement. The outlet nozzle 106 has one endwelded to the reactor shroud 107 (internal to the reactor vessel shell103) and an opposite end configured for welding to an inlet nozzle of asteam generator vessel which receives primary coolant from the reactorvessel 100 to produce steam for a Rankine power generation cycle (notshown). Such a steam generator is shown for example in commonly-ownedU.S. Pat. No. 9,892,806, which is incorporated herein by reference. Theinlet nozzle 105 has one end welded to the reactor vessel shell 103 andan opposite end configured for welding to an outlet nozzle of the steamgenerating vessel. Inlet nozzle 105 is in direct fluid communicationwith the annular downcomer region 108. Regarding the primary coolantflow path, primary coolant in a cooled state from the steam generatorenters reactor vessel 100 through inlet nozzle 105 and flows downwardthrough the annular downcomer region to the bottom of the reactorvessel. The flow enters the reactor core 120 and is heated by the fuelassemblies 124 causing the primary coolant to rise into shroud 107 ofthe upper internals unit 110 via natural circulation in one embodiment.The heated primary coolant rises through the flow tubes 166 and collectsin the upper flow plenum 165. The primary coolant exits the upper flowplenum 165 through a lateral opening 168 in the shroud 107 (see, e.g.FIG. 25) and enters the outlet nozzle 106 from which the coolant flowsback to the steam generator.

The foregoing reactor vessel, nozzles, and components of the upperinternal unit 110 may be formed of a preferably corrosion resistantmetal, such as stainless steel for example in one non-limitingembodiment. Other suitable metallic materials however may be used anddoes not limit the invention.

The lower internals unit 112 of the reactor which defines the fuel core120 will now be further described. Referring to FIGS. 4-19, the fuelcore comprises a plurality of vertically-extending fuel assemblies 124each including a multiplicity of hollow fuel rods 160 each containingnuclear fuel pellets such as uranium which generates heat to heat theprimary coolant in the reactor vessel 100. The fuel assemblies 124 mayhave a square cross-sectional shape in one embodiment and include a topflow nozzle structure 161 including lifting members 162 for rigging tomove and place the fuel assembly in the core.

A vertically elongated metallic cylindrical reflector 121 surrounds thecore of fuel assemblies 124 which helps to protect the reactor pressurevessel 100 from embrittlement caused by fast spectrum neutrons (>1 MeV),while additionally reflecting thermal neutrons back towards the core.Reflector 121 has an annular body in transverse cross section thatdefines an interior space 123 configured to receive the plurality offuel assemblies 124 therein. Reflector 121 may have substantially thesame diameter as the upper shroud 107 which may engage and be supportedby the reflector. In one embodiment, the reflector 121 may be comprisedof a plurality of vertically stacked annular ring segments 122 tofacilitate assembly of the reflector within the lower portion of thereactor vessel 100. The reflector segments 122 are tightly abuttedtogether to form an integral cylindrical wall. In one embodimentconnecting rods 176 which extend vertically from the upper-mostreflector segment 122 to the lower-most segment may be provided to tiethe structure together and properly align each segment rotationally tothe adjoining segments. The connecting rods 176 allow for a degree ofthermal expansion between the reflector segments 122. A plurality ofvertically-extending cooling conduits 139 may be provided which areintegrally formed completely through each segment 122 from top to bottomfor cooling the cylindrical reflector 121. Primary coolant may thereforecirculate vertically through the concentrically aligned conduits in eachsegment for cooling. The connecting rods 176 ensure that the coolingconduits 139 are properly aligned to adjoining cooling conduits in otherreflector segments 122. In other possible embodiments, it bears notingthat the reflector may comprise a single monolithic annular cylindricalstructure or body. The reflector 121 may be made of a suitable metal,which preferably may be corrosion resistant such as stainless steel orothers.

As shown in FIG. 4, reflector 121 may be machined, cast, or otherwiseformed to create a polygonal-shaped multiple stepped interior wallsurface 200 configured to engage complementary configured keyingstructures of the upper and lower core plates 125 and 126 when attachedto the reflector. This rotationally locks the core plates 125, 126 inposition relative to the reflector, as further described herein. Theconnecting rods 176 noted above ensures that the stepped facets orsurfaces of each reflector ring segment 122 are properly aligned witheach other in adjoining segments in the vertical stack.

The fuel core 120 further includes a lower core plate 126 and aplurality of vertically elongated channel boxes 130 supported by thelower core plate. When the upper internals unit 110 is placed on top ofthe fuel core 120 in the reactor vessel 100, the channel boxes 130 willextend vertically between the upper and lower core plates 125, 126. Thechannel boxes 130 each provide a flow conduit or channel for flow ofprimary coolant through the fuel assemblies 124 disposed in the boxes.As shown in FIGS. 30 and 31 particularly, each channel box 130 istransversely/laterally separated from adjacent channel boxes byperipheral water gaps 157 which are filled by primary coolant duringnormal operation of the reactor.

Referring now generally to FIGS. 26-42, the channel boxes 130 may eachdefine a vertical centerline CL and have a generally rectangularprismatic or cuboid configuration in one embodiment as illustrated.Channel boxes 130 are longitudinally and vertically elongated structureseach including a top end 136 and bottom end 137, and plurality ofsidewalls 138 extending between the ends. Bottom end 137 may include abase reinforcement 137 a for abutting engaging the lower core plate 126when inserted in the core to prevent damage to the channel box 130.Channel boxes 130 may have a height that extends for a majority of, andin some embodiments as shown substantially the entire height of thecylindrical reflector 121. Each channel box 130 in one embodiment isformed by a plurality of perpendicularly intersecting outer walls 131and inner walls 132 collectively defining a plurality of verticallongitudinally-extending interior open channels or cells 133 configuredfor holding a fuel assembly 124. Each cell 133 has a transverse crosssectional area configured for receiving and holding no more than asingle or solitary nuclear fuel assembly 124 which may have a squarecross-sectional shape in the non-limiting illustrated embodiments. Theouter walls 131 may thus be arranged perpendicularly to each other anddefine a perimeter of each box. The inner walls 132 may also be disposedperpendicularly to each other and intersect at right angles to form acruciform configuration (in transverse cross-sectional view) as shown.

In one embodiment, the array of channel boxes 130 provided may include acombination of boxes having either a square or a rectangular transversecross section in shape for placement in different regions of the fuelcore 120. The square channel boxes (see, e.g. FIGS. 32-41) have fourcells 133 with cruciform inner walls 132 and may comprise a majority ofthe number of boxes positioned in both the inboard and portions of theperipheral or outboard regions of the fuel core. The rectangular channelboxes (see, e.g. FIG. 42) have two cells 133 with a single straightinner wall 132 and may be selectively positioned in certain outboardregions of the fuel core to advantageously maximize the number of fuelassemblies 124 than can be packed into the core.

In one exemplary construction, the outer and inner walls 131, 132 of thechannel boxes 130 may be formed by a combination of longitudinalstructural metal plates which are assembled and welded together alongtheir abutting longitudinal edges 140 to form the integral weldedstructures depicted in the figures which have substantial strength andstiffness resistance to bowing or bending normal to the verticalcenterline of the boxes. FIG. 36 is an exploded view of the plates inone representative assembly of a square channel box 130. In thisembodiment, the square channel box 130 may be formed by four L-shapedexterior wall plates of single thickness welded together bylongitudinally-extending welds 141 along their mating longitudinal edges140 to form the outer walls 131 creating the channel box's perimeter.The inner walls 132 may be formed by two L-shaped interior wall platesof single thickness placed back to back at their corner which may bewelded together to create a cruciform structure with perpendicularlyintersecting walls. In one construction, the free longitudinal edges ofthe interior wall plates may each be welded to and at the intersectionof abutted mating longitudinal edges 140 of two exterior wall plates.The interior wall plates of the inner walls 132 therefore intersect theouter walls 131 perpendicularly at right angles.

It bears noting that the inner walls 132 formed by the L-shaped interiorwall plates form a cruciform shaped internal lateral bracing (intransverse cross section) for each channel box 130. This structurallyreinforces the channel box 130 which creates a robust construction thatresists radiation induced bowing and bending forces acting in a planetransverse to the vertical centerline CL of the channel box (andlongitudinal axis of the fuel core 120). This is a common problem withfuel assembly box structures used in BWR reactors which have completelyopen center regions that lack such interior walls or bracing andsubsequently cannot effectively resist radiation bowing which adverselyprevents proper and complete insertion of the control rods in the fuelcore over time. The structurally reinforced channel boxes 130 disclosedherein represent an advance over such unbraced prior channel box fuelassembly support structures.

In addition, it bears noting that the close-packed nature of the fourfuel assemblies contained within one channel box 130, contrary tocurrently operating boiling water reactors (BWRs) which have eachindividual assembly surrounded by its own channel box, providesincreased operational safety for the conditions found in the presentsmall modular reactor (i.e. natural circulation primary coolant with arelatively low inlet temperature) by reducing the moderator-to-fuelratio.

The foregoing construction of the channel boxes and arrangement ofinterior cells 133 benefits the neutronics of the nuclear reactor byeliminating water gaps between fuel assemblies 124 contained in thecells. Each interior cells shares a common inner wall 132 with at leastone other cell and is separate therefrom by the single thickness of thecommon inner wall. No open gaps or double walls are formed between cells133 in one embodiment.

In one embodiment, the channel boxes 130 may be constructed of azirconium-based metal alloy. Other suitable metallic materials howevermay be used.

The lower core plate 126 is coupled to the bottom of the cylindricalreflector 121. Referring now to FIGS. 15-19, the lower plate core plate126 includes a top 151 and bottom 152 defining upward and downwardfacing surfaces. Lower core plate 126 generally comprises asubstantially planar circular metallic body defining an array comprisinga plurality of upwardly open receptacles 143 each complementaryconfigured to and engaging a respective bottom end 137 of one of thechannel boxes 130 for support. The receptacles 143 include a combinationof square receptacles for receiving and engaging square channel boxes130 and rectangular channel boxes for rectangular channel boxes. Eachreceptacle therefore has an upwardly facing support surface having acomplementary configuration to the bottom end surface of the channel box130 to be received therein. Accordingly, each receptacle compriseseither a cruciform support surface 148 (for square channel boxes) whichengages a complementary configured cruciform bottom end surface portionof the channel box, or linear support surface 149 (for rectangularchannel boxes) which engages a linear bottom end surface portion of thechannel box. The support surfaces 148 and 149 are defined by the tops ofrecessed vertical divisional walls 153 within each receptacle 143 formedby the structural body of the lower core plate 126. When the bottom ends137 of the channel boxes 130 are engaged with the receptacles andsupport surfaces, the division walls 153 fluidly separate the flow ofprimary coolant upwards through the open cells 133 of each channel box130 to avoid or minimize any cross flow into adjacent cells. Thedivision walls 153 therefore define a plurality of sub-cells 177 withineach receptacle 143 (four within a square receptacle and two within arectangular receptacle as shown).

Lower core plate 126 includes a plurality of flow orifices 146 which arein fluid communication with the bottom flow plenum 178 formed beneaththe lower core plate in the reactor vessel 100 (see, e.g. FIG. 3). Eachsub-cell 177 in the receptacles 143 of the lower core plate 126 has anassociated flow orifice 146 which are in fluid communication with itsrespective channel box 130 and fuel assembly 124 therein. The squarereceptacles 143 may therefore have four orifices 146 and rectangularreceptacles two orifices. The flow orifices 126 have diameters selectedto produce the desired primary coolant flow rate through each channelbox 130 and fuel assembly 124.

The lower core plate 126 further comprises a plurality of upstandingguide walls 145 arranged in a perpendicularly intersecting array asshown. The guide walls 145 slideably engage and guide the bottom ends137 of the channel boxes 130 into the upwardly open receptacles 143 ofthe lower core plate 126 when the channel boxes are initially insertedinto the fuel core 120. In addition, the guide walls 145 further act tohelp isolate and separate the flow from the receptacles 143 in the lowercore plate 126 into the channel boxes 130 to minimize possible crossflow.

In some embodiments, lower core plate 126 may further include apolygonal-shaped and raised annular anti-rotation lip 144 protrudingupwards from a top surface of the lower core plate. The anti-rotationlip 144 extends circumferentially around a peripheral portion of thelower core plate as shown. The anti-rotation lip 144 may have a multiplestepped configuration which matches and engages the complementaryconfigured multiple stepped interior surface 200 of the cylindricalreflector 121 in a similar manner to the upper core plate 125 tooperably key and lock the lower core plate 126 in rotational positionrelative to the cylindrical reflector. When the lower core plate 126 isengaged with cylindrical reflector 121, the anti-rotation lip 144 isinserted inside a bottom end of the cylindrical reflector and peripheralportions of the circular flat body of the lower core plate outboard ofthe anti-rotation lip engage a downward facing bottom end surface of thecylindrical reflector (see, e.g. FIG. 8). A stepped shoulder structureis therefore formed between the protruding anti-rotation lip 144 andadjoining upward facing flat top surface of the lower core plate 126. Itbears noting that the guide walls 145 may have a greater height than theanti-rotation lip 144 and are arranged to avoid engaging the reflector121.

In some embodiments, the planar peripheral portions of the lower coreplate 126 outboard of the raised anti-rotation lip 144 may include aplurality of through flow holes 147 (see, e.g. FIGS. 16 and 17). Theflow holes 147 substantially line up vertically and axially up with thecooling conduits 139 in the cylindrical reflector. This allows primarycoolant in the reactor vessel to circulate and flow through the lowercore plate and reflector ring segments 122 to cool the reflector 121.Flow holes 147 are in fluid communication with the lower flow plenum 178(see, e.g. FIG. 3).

In one embodiment, the metal upper and lower core plates 125, 126 mayeach be formed of a suitable corrosion resistant metal such stainlesssteel. Other metals may be used.

Referring to FIGS. 3-8 and 10, the lower core plate 126 and cylindricalreflector 121 are supported in the reactor vessel 100 by an open spaceframe type core support member 180 abuttingly engaging bottom surfacesof the cylindrical reflector and the lower core plate. Support member180 may comprise a vertically-extending central hub 181 and plurality ofarms 182 extending radially therefrom and angularly spaced apartrelative to each other. The arms each include an arcuately convex bottomsurface 183 configured to engage an arcuately concave surface inside thebottom head 102 of the reactor vessel 100 which receives the fuel core.The lower core plate 126 may contain polygonal shaped notches 184 whichengage and locate each arm 182 of the support member 180 (see also FIG.17-19). The core support member 180 raises the core above the bottom ofthe reactor vessel 100 and defines a bottom flow plenum 178 beneath thelower core plate 126. Flow traveling downwards from the annulardowncomer 108 of the reactor vessel enters flow plenum 178 and reversesdirection to then flow upwards through the flow orifices 146 of thelower core plate into the channel boxes 130 and fuel assemblies 124. Thebottom head 102 of reactor vessel 100 may include a drain nozzle 179 influid communication with the bottom flow plenum 178 for draining primarycoolant out of the reactor vessel. In some non-limiting embodiments, thesupport member 180 may be welded to the lower core plate and/or thelower-most segment 122 of the cylindrical reflector 121. Support member180 may be preferably made of a suitable strong corrosion resistantmetal, such as stainless steel as one non-limiting example.

FIGS. 28-30 show the cruciform control rod assembly in greater detail.Each control rod 150 comprises a cylindrical shaft 155 having a top endconfigured to engage a control rod drive mechanism (not shown) mountedabove the fuel core 120 and a plurality of perpendicularly intersectingblades 154 coupled to a bottom end of the shaft. The blades 154 arearranged to form a cruciform shape in transverse cross section as shown.The blades may incorporate a neutron absorbing material such as forexample without limitation B4C (boron carbide) powder, hafnium plates, acombination thereof, or other materials. The blades may be formed ofmetal plates such as steel or zircalloy creating a structure that formsthe cruciform. To facilitate smooth sliding insertion of the controlrods 150 into the peripheral water gaps 157 created between the channelboxes 130 such as in the corner regions between adjacent channel boxesin the core as shown (see, e.g. FIGS. 30-31), the blades 154 mayoptionally include one or more protruding sliding bearing 156 which maybe a raised protrusion or tab, roller type bearing, ball, or otherelement on the blade which functions as a bearing to slideably engagethe sidewalls of the channel boxes 130 when the blades are movedupwards/downwards in the fuel core 120.

In some embodiments, some of the peripheral channel boxes 130 of thefuel core 120 may have removably insertable reflector inserts 158disposed in one or more of the cells 133 as shown in FIG. 43. Inserts158 may be assemblies which may comprise either solid stainless steelpins or stainless steel tubes that contain neutron reflection materialsfor a number of purposes including, but not limited to, improved neutroneconomy for the reactor core and specific isotope production. Thesereflector assemblies facilitate varying reflector material axially toallow for optimization of power distributions in a reactor which has alarge axial gradient in physical characteristics, such as in the presentsmall modular reactor.

An exemplary method for assembling a nuclear reactor will be brieflydescribed. The core support member 180, lower core plate 126, andlower-most reflector ring segment 122 may first be inserted into thereactor vessel 100. The lower core plate 126 is rotationally keyed tothe reflector segment 122 via the raised annular anti-rotation lip 144protruding upwards from a top surface of the lower core plate. Thesupport member 180 engages the bottom head 102 of the reactor vessel.Additional reflector segments 122 may next be stacked upon the alreadyemplaced segment 122 one by one to build up successive courses of thesegments until the complete reflector 121 is created. The channel boxes130 may next be lowered into the reactor vessel 100 to abuttingly engagetheir bottom ends with a respective receptacle 143 in the lower coreplate 126. A single fuel assembly 124 is lowered into the rev andinserted into each channel box 130. The control rods 150 may next beinserted into the core between the channel boxes 130 in the peripheralwater gaps 157 at the positions described and shown herein. Thisessentially completes the lower internals unit 112 installation in thereactor vessel.

The fully preassembled self-supporting upper internals unit 110 may nextbe positioned over and lowered into the reactor vessel and stacked ontop of the cylindrical reflector 121. In the process, specifically, theupper core plate 125 of the upper internal unit is engaged with androtationally keyed to the upper-most reflector segment 122 via themating multiple stepped surfaces 200, 190 of the reflector segment andupper core plate respectively. This ensures proper alignment of thecruciform control rod openings 171, 170 in the upper core andintermediate support plates 125, 139 respectively. When the upper andlower internals units 110 and 112 (i.e. fuel core 120) are therefore nowstacked together in the reactor vessel 100, each channel box 130 of thecore will be vertically aligned with a corresponding flow tube 166 ofthe upper internals unit creating an array of unified primary coolantflow paths from the bottom flow plenum 178 at bottom end of the reactorvessel to the outlet nozzle 106 near the top. Additional remainingpreparations may be completed and the top head 101 of the reactor vessel100 may eventually be closed.

When core refueling is required, the reactor vessel is opened and theupper internals unit 110 is first removed. The control rods 150 remainin place within the fuel core 120 to control reactivity during therefueling outage. The required fuel assemblies 124 are removed andreplaced as needed.

While the foregoing description and drawings represent exemplaryembodiments of the present invention, it will be understood that variousadditions, modifications and substitutions may be made therein withoutdeparting from the spirit and scope and range of equivalents of theaccompanying claims. In particular, it will be clear to those skilled inthe art that the present invention may be embodied in other forms,structures, arrangements, proportions, sizes, and with other elements,materials, and components, without departing from the spirit oressential characteristics thereof. In addition, numerous variations inthe methods/processes. One skilled in the art will further appreciatethat the invention may be used with many modifications of structure,arrangement, proportions, sizes, materials, and components andotherwise, used in the practice of the invention, which are particularlyadapted to specific environments and operative requirements withoutdeparting from the principles of the present invention. The presentlydisclosed embodiments are therefore to be considered in all respects asillustrative and not restrictive, the scope of the invention beingdefined by the appended claims and equivalents thereof, and not limitedto the foregoing description or embodiments. Rather, the appended claimsshould be construed broadly, to include other variants and embodimentsof the invention, which may be made by those skilled in the art withoutdeparting from the scope and range of equivalents of the invention.

What is claimed is:
 1. A nuclear fuel core for a nuclear reactor, thefuel core comprising: a longitudinal axis; an upper core plate; a lowercore plate; a plurality of vertically elongated prismatic channel boxesextending between the upper and lower core plates, each channel boxcomprising a plurality of outer walls and inner walls collectivelydefining a plurality of longitudinally-extending interior cells eachcontaining a single nuclear fuel assembly, each channel box separatedfrom adjacent channel boxes by peripheral water gaps formed between theouter walls of the channel boxes; a plurality of cruciform control rodsslideably inserted through the peripheral water gaps from above theupper core plate for vertical movement between the channel boxes; acylindrical reflector circumferentially surrounding the channel boxes,the upper and lower core plates engaging opposing ends of the reflector;wherein the fuel assemblies within each channel box are separated fromeach other by the inner walls.
 2. The fuel core according to claim 1,wherein the control rods are disposed at junctions of corner regionsbetween adjacent channel boxes.
 3. The fuel core according to claim 2,wherein the upper core plate includes a plurality of cruciform openingseach slideably receiving one of the control rods therethrough forinsertion into the fuel core.
 4. The fuel core according to claim 1,wherein the upper core plate is an open grid structure engaging upperportions of the channel boxes and defining a plurality of rectilinearopen cells each axially aligned with one of the cells of the channelboxes.
 5. The fuel core according to claim 4, wherein the upper coreplate has a polygonal-shaped perimeter with a multiple steppedconfiguration which engages a complementary configured multiple steppedinterior surface of the cylindrical reflector to operably key and lockthe upper core plate in rotational position relative to the cylindricalreflector.
 6. The fuel core according to claim 1, wherein the channelboxes have a rectilinear transverse cross-sectional shape and the innerwalls have edges that perpendicularly intersect the outer walls.
 7. Thefuel core according to claim 6, wherein the channel boxes includes acombination of rectangular channel boxes having a rectangular transversecross-sectional shape disposed around exterior portions of the fuel coreand square channel boxes having square transverse cross-sectionalshapes.
 8. The fuel core according to claim 1, further comprising anupper internals unit stacked vertically on top of the cylindricalreflector, the upper internals unit comprising a plurality of verticallyoriented flow tubes axially aligned with and in fluid communication withthe cells of the channel boxes.
 9. The fuel core according to claim 1,wherein the cylindrical reflector is formed of multiple verticallystacked metallic annular segments abutted together to form an integralstructure.
 10. The fuel core according to claim 9, wherein thecylindrical reflector includes a plurality of vertically coolingconduits extending from a top to a bottom of the reflector for coolingthe reflector.
 11. A nuclear fuel core for a nuclear reactor, the fuelcore comprising: a vertically elongated reactor vessel defining aninternal cavity and a longitudinal axis; an upper internals unitdisposed in the internal cavity, the upper internals unit comprising: atop support plate, an upper core plate spaced vertically apart from thetop support plate, and an intermediate support plate spacedtherebetween; a plurality of flow tubes extending between theintermediate support plate and upper core plate; and a plurality of tierods coupling the top support plate to the upper core plate through theintermediate support plate to form a self-supporting assemblageremovably insertable in the reactor vessel as a single unit; a lowerinternals unit disposed in the internal cavity comprising a plurality offuel assemblies defining a fuel core, the lower internals unit furthercomprising: a plurality of vertically elongated channel boxes extendingbetween the upper core plate of the upper internals unit and a lowercore plate, each channel box comprising a plurality of outer walls and aplurality of inner walls collectively defining a plurality oflongitudinally-extending interior cells each containing a single nuclearfuel assembly; and a cylindrical reflector circumferentially surroundingthe channel boxes, the upper and lower core plates disposed on opposingends of the reflector; wherein each channel box is vertically alignedwith a respective flow tube in the upper internals unit to form a flowpath therebetween; wherein each channel box is separated from adjacentchannel boxes by peripheral water gaps formed between the outer walls ofthe channel boxes.
 12. The fuel core according to claim 11, wherein thefuel assemblies within each channel box are separated from each other bythe inner walls.
 13. The fuel core according to claim 12, furthercomprising a plurality of cruciform control rods slideably inserted inthe peripheral water gaps for vertical movement therein to controlreactivity in the reactor.
 14. The fuel core according to claim 11,further comprising a cylindrical shroud disposed in the internal cavitystacked on top of the cylindrical reflector, the shroud surrounding theupper internals unit component.
 15. The fuel core according to claim 14,wherein an upper flow plenum is formed between top and intermediatesupport plates in the shroud and a control rod compartment is formedbetween the intermediate support plate and upper core plate in theshroud, the control rod compartment configured to receive a portion ofthe control rods withdrawn from the fuel core.
 16. The fuel coreaccording to claim 13, wherein the control rods are disposed atjunctions of corner regions between adjacent channel boxes.
 17. The fuelcore according to claim 16, wherein the upper core plate includes aplurality of cruciform openings each slideably receiving one of thecontrol rods therethrough for insertion into the fuel core.
 18. The fuelcore according to claim 1, further comprising an upper internals unitstacked vertically on top of the cylindrical reflector, the upperinternals unit comprising the flow tubes which are axially aligned withand in fluid communication with the cells of the channel boxes.